Manufacturing methods for high density micro-channel arrays

Abstract

This thesis explores two distinct methods of micro-array manufacture for high throughput pharmaceutical scanning. The first method, impact shaping of polymers, is a novel, inexpensive way to form large numbers of small channels or wells in plastics. The impact method uses the kinetic energy from a ram to punch holes into a polymer sample without melting the bulk of the workpiece. The second method is electrical discharge machining (EDM) of silicon, which machines high aspect ratio holes arranged in high density arrays on silicon wafers. The method may be viewed as complementary to current plasma etching techniques and lithography. Several testing platforms were devised for the creation of the plastic well arrays based on the high speed ram principle. A modified Charmilles Roboform 30 machine was used to create the silicon arrays. While creating high volume manufacturing methods for will required additional work, both processes were fundamentally successful, producing individual arrays of acceptable quality. Both methods hold promise for manufacture of accurate, inexpensive, and useful replacements for current plate technology.